CORROSION PROTECTION

Pencegahan Korosi
Metoda pengendalian korosi ada 6, yaitu :
1. Pemilihan Material
jenis material yang digunakan harus memiliki ketahanan korosi sesuai dengan lingkungan tempat
aplikasinya.

2. Proteksi Katodik
Proteksi katodik ada dua macam yaitu :
a. Anoda Korban,.
b. Impressed current

3. Proteksi Anodik
Umumnya dilakukan pada logam yang bersifat pasif . Lapisan pasif akan dipertebal dengan
memberikan potensial ke arah anodik.

4. Inhibitor
Penambahan zat kimia dengan konsentrasi rendah ke media lingkungan untuk memperlambat laju
korosi logam

5. Design
Perbaikan design yang lebih tahan terhadap korosi

6. Coating
Permukaan logam dilapisi dengan bahan logam maupun non logam yang terdiri dari campuran
senyawa kimia untuk mencegan kontak langsung antara logam yang dilindungi dengan lingkungan.
1. PEMELIHAN MATERIAL

selection of proper material for a particular corrosive service

No Environment Proper material

1 Nitric acid Stainless steels

2 Caustic Nickel and nickel alloys

3 Hydrofluoric acid Monel (Ni-Cu)

4 Hot hydrochloric acid Hastelloys (Ni-Cr-Mo) (Chlorimets)

5 Dilute sulfuric acid Lead

No Environment Proper material

6 Nonstaining atmospheric exposure Aluminium

7 Distilled water Tin

8 Hot strong oxidizing solution Titanium

9 Ultimate resistance Tantalum

10 Concentrated sulfuric acid Steel

 2. PROTEKSI KATODIK
a. Pengendalian Korosi dengan Proteksi Katodik ANODA KORBAN
Proteksi katodik adalah metode yang sering diterapkan untuk pengendalian
korosi besi yang dipendam dalam tanah, seperti pipa ledeng, pipa pertamina,
dan tanki penyimpan BBM.
Logam reaktif seperti magnesium dihubungkan dengan pipa besi. Oleh karena
logam Mg merupakan reduktor yang lebih reaktif dari besi, Mg akan teroksidasi
terlebih dahulu.

Reaksi yang terjadi dapat ditulis sebagai berikut.

Anode : 2Mg(s) ⎯⎯→ 2Mg2+(aq) + 4e–
Katode : O2(g) + 2H2O (l) + 4e– ⎯⎯→ 4OH–(aq)
Reaksi : 2Mg(s) + O2(g) + 2H2O ⎯⎯→ 2Mg(OH)2(s)

logam magnesium (yang dikorbankan) harus selalu selalu diperiksa agar jangan
sampai habis karena berubah menjadi hidroksidanya
b. Sistem Arus Tanding (Impressed Current)
Berbeda dengan system anoda korban, sumber arus pada system arus tanding berasal dari luar,
biasanya berasal dari DC, dimana kutub negative dihubungkan ke struktur yang dilindungi dan
kutub positif dihubungkan ke anoda. Arus mengalir dari anoda melalui elektrolit ke permukaan
struktur, kemudian mengalir sepanjang struktur dan kembali ke rectifier melalui konduktor
elektris. Karena struktur menerima arus dari elektrolit, maka struktur menjadi terproteksi.

(-)

(+)

(campuran besi dan silikon), grafit, campuran

logam oksida, platina dan niobium
 3. PROTEKSI ANODIK

Proteksi Anodik pada Tangki

Penyimpanan Asam di Lingkungan Industri

Proteksi anodik adalah metoda pengendalian korosi dengan membuat logam menjadi
pasif (terbentuk lapisan oksida protektif). Caranya dengan memberikan arus agar
potensial logam menjadi lebih anodik dan masuk ke daerah pasif (harga potensialnya
lebih besar dari potensial korosi). Proteksi anodik dilakukan pada logam yang mempunyai
sifat aktif-pasif / mampu pasif (dapat dipasifasi dan teraktifasi kembali, berdasarkan
diagram Potensial – pH) arus yang dipasok agar logam menjadi pasif harus dapat
melebihi ikritik
4. PENGENDALIAN KOROSI DENGAN PENAMBAHAN INHIBITOR

Inhibitor adalah zat kimia yang ditambahkan ke dalam suatu lingkungan korosif dengan kadar
sangat kecil (ukuran ppm) guna mengendalikan korosi :

Anodic inhibitors adalah senyawa kimia yang mengendalikan korosi

dengan cara menghambat transfer ion-ion logam ke dalam air. Contoh inhibitor
anodik adalah senyawa kromat dan senyawa molibdat.

Cathodic inhibitors adalah senyawa kimia yang mengendalikan korosi dengan

cara menghambat salah satu tahap dari proses katodik, misalnya penangkapan
gas oksigen (oxygen scavenger) atau pengikatan ion-ion hidrogen. Contoh inhibitor
katodik adalah hidrazin, tannin, dan garam sulfit.

Inhibitor campuran
Inhibitor campuran mengendalikan korosi dengan cara menghambat proses di
katodik dan anodik secara bersamaan. Pada umumnya inhibitor komersial berfungsi
ganda, yaitu sebagai inhibitor katodik dan anodik. Contoh inhibitor jenis ini adalah
senyawa silikat, molibdat, dan fosfat.

Inhibitor teradsorpsi
Inhibitor teradsorpsi umumnya senyawa organik yang dapat mengisolasi
permukaan logam dari lingkungan korosif dengan cara membentuk film tipis yang
teradsorpsi pada permukaan logam. Contoh jenis inhibitor ini adalah
merkaptobenzotiazol dan 1,3,5,7–tetraza–adamantane.
5. PENGENDALIAN KOROSI DENGAN PERBAIKAN DESIGN
5. PENGENDALIAN COATING
(PROVIDE BARRIER BETWEEN METAL & ENVIRONMET)

Difference between coating and thin film :

(If thickness of layer formed on substrate)

 1µm, then known as coating
 < 1 µm, then known as thin film

All paint on structural application in our daily life is called as

coating, as they are of thickness >1 µm
Why coating is necessary for aerospace component?
When space vehicles are moving there are many conditions which affect the
body of vehicle are:

 High friction with air

 Fatigue stress
 water traps
 Temperature
 Pressure
 INORGANIC COATING

Oxide layer

A. Oxide Coating (Al; Mg; Ti; Niobium, Th)

is an electrochemical process that converts the metal
surface into a decorative, durable, corrosion-resistant,
anodic oxide finish

B. Oxide Coating For Ferro (Steel) Blacking

ferrous alloy and the hot oxide bath produces a
Inorganic Coating magnetite (Fe3 O4)

Conversion Coating
A. Phosphate Layer for steel
Chemical Conversion Coating of steel using phosphate compound

B. Chromate layerfor Aluminium

A. Oxide Coating (Al; Mg; Ti; Niobium, Th)
Step 1: Place in the cleaner tank for 5 to 10 minutes to remove dust and
light oils and then rinse. We like to have the parts dipped into and out of
the cleaner tank a number of times while processing to be sure they are
completely clean and free of water break
Step 2: Place in the etch tank for 30 seconds to 2 minutes,
depending upon the aggressiveness of the etch solution,
then rinse thoroughly.
Step 3: Swish the parts around in the Deox tank, then
place into the Deox tank to remove any oxidation (or smut)
and then leave parts there for 5 to 15 minutes. Rinse
completely.
Step 4: Dip two or three times to work any air bubbles out of the parts, then
place in the aluminum anodize tank. Start the rectifier and let it ramp up to
the required voltage or amperage. Note that most specifications call out for
a ramp time of 3 to 5 volts per minute. Vigorous air and solution agitation (if
not mechanical agitation too) is required for full, consistent coverage.
When a acid solution is electrolysis processed, the anode normally emits oxygen but not in a
case of aluminum anodes. The oxygen from the aluminum anode immediately binds before
gasifying with dissolved surface layer metal and forms an aluminum oxide. The layer forming
process is shown in [Fig.2] below.
A barrier layer forms during the initial phase of the electrolysis advancing to a formation of
porous layer. As the process progresses, this porous layer grows to a certain thickness. As can be
seen on the diagram, an anodized layer is made up of a electrically conductive but non-growing
barrier layer, and isolating but growing porous layer
Step 5: Put parts into the Hot Sealer tank (usually just boiling deionized
water) for the 15 to 30 minute process time. Once parts come out of the
sealer tank, they should be blown off with clean, dry air until they are dry
This is the final step in the anodizing process. It closes the pores in the anodic film,
locking in colors and creating a surface resistance to staining, abrasion, and color
degradation.
 Reactants Products

2Al(s) + 3H2O(aq) - 6e- = Al2O3(s) + 6H+(aq)

Aluminium Water Electrons Aluminium Protons

oxide

Reactants Products

2Al + 3H2O - 6e- = Al2O3 + 6H+

2 atom 3 molecules 6 molecules 1 molecule 6 ions
2 mol 3 mol 6 mol 1 mol 6 mol
2 x 26.98 g 3 x 18.016 g 6F 1 x 101.96 g 6 x 1.008 g
• Anode (aluminium)
2Al(s) + 3H2O(l) - 6e- = Al2O3(s) + 6H+(l)

• Cathode (e.g., stainless steel)

6H+(l) + 6e- = 3H2 (g)

• Cell (overall process)

2Al(s) + 3H2O(l) + 6H+(l) = Al2O3(s)+ 6H+(l)+ 3H2(g)
MIL-A-8625, which defines three types of aluminium anodization.
 Type I is chromic acid anodization,
 Type II is sulfuric acid anodization, and
 Type III is sulfuric acid hardcoat anodization.
Other anodizing specifications include more MIL-SPECs (e.g., MIL-A-63576), aerospace
industry specs by organizations such as SAE, ASTM, and ISO (e.g., AMS 2469, AMS
2470, AMS 2471, AMS 2472, AMS 2482, ASTM B580, ASTM D3933, ISO 10074, and BS
5599),

Standards for titanium anodizing are given by AMS 2487 and AMS 2488

Standards for magnesium anodizing are given in AMS 2466, AMS 2478, AMS 2479,
and ASTM B893
 A. Oxide Coating For Ferro (Steel)

Black oxide, also know as gun bluing, is a conversion coating formed by a chemical
reaction produced when parts are immersed in the alkaline aqueous salt solution
(NaOH; NaNO3; NaNO2) operated at approximately 140 degrees C.
The reaction between the iron of the ferrous alloy and the hot oxide bath
produces a magnetite (Fe3 O4)
Oxide chemistries are usually proprietary a common oxidizer is sodium
chlorite with sodium hydroxide. Other ingredients vary from vendor to vendor.
The oxide bath must be quite hot, usually 140 to 150°F or hotter.
The process takes 15 to 30 minutes to complete
The Black Oxide process includes:
 Cleaning
 Rinsing
 Oxide bath
 Rinse
And in most cases a supplementary top coat, usually
an oil to improve corrosion protection

Applicable “Hot” Black Oxide Specifications

• SAE Aerospace AMS 2485K
• Mil C-13924D-Class 1*
• Ford Motor ESF-M6P3-A
• General Motors GM-4347-M
• Toyota TSH7603G
• Steelcase ES 1-02-02
INORGANIC COATING
Chemical Conversion Coating : membuat permukaan metal menjadi pasif

 Corrosion Inhibitor
 Decorativ Finish
 Retain Electrical conductivity

Phosphate Layer For STEEL

Type Coating
• Zn-Phospahte Coating
• Mn-Phosphate Coating
• Fe-Phosphate Coating
PHOSPHATING PROCESS SEQUENCE
 Type Coating weight (spray) Type of coating
Iron Phosphate 2.1 to 4.3 mg/dm2 amorphous and iridescent in
appearance.
zinc phosphate 10.7 and 430.0 mg/dm2 crystalline, gray in color

manganese phosphate 108 and 430 mg/dm2 brilliant black in appearance

and consists of a compact
aggregation of very large
crystals.
 INORGANIC COATING
C. Chromate Conversion Coating For ALUMINIUM

Classifications of Chemical Conversion Coatings

Chemical conversion coatings are generally classified as follows:
Class 1A Coatings: coatings for maximum protection against corrosion and maximum
paint adhesion.
Class 3 Coatings: coatings for corrosion (thinner than Class 1A) and intended for
electrical applications where low electrical resistance is required relative to Class 1A
coatings and anodizing
Generally, chemical conversion coatings are specified using Military Specification
MIL-DTL-5541F
The formation of CCC has been described as a process resulting from a redox reaction
between chromate ions in solution and aluminum.
At low pH (< 2) chromates exists as either HCrO4- or Cr2O72-.
Both of these two ions are strong oxidizing agents and have high reduction potentials.
The formation mechanism of CCC is given below:
C. Chromate Conversion Coating
The key to a successful coating project is surface
preparation. We want a surface that is clean and
suitably roughened.

Adhesion is the most important attribute of a coating.

A clean surface with the proper profile provides a
surface to which a coating can adhere.
A clean surface should be free of all:
• Oil
• Grease
• Dust
• Dirt
• Mill scale
• Rust
• Coating
• Oxide
• Corrosion Product
• Other foreign matter

Mill scale is cathodic to the steel. If mill scale is left on the surface, and painted over,
the steel will rust and sacrifice itself trying to protect the mill scale.
METALIC COATING

The diffusion coating is a process which is sprayed a layer of coating and that
can be diffused in a substrate. Thus we can improve the density, ductility,
resistance to oxidation and corrosion of coated substrate and also as the
mechanical strength of the coating.

DIFFUSED ALUMINUM coating: One of the main systems of metallic coating

used to work at high temperature as a protective layer behavior wear and
corrosion. Aluminum diffused surface layers linked to form FeAl, NiAl, Coal,
AlSi, depending on the metal substrate. The layers of protection arises from
the formation of protective films AL ² O ³. The different compounds have
different hardness can reach up to 60HRC (700HV). This layer acts as a barrier
to diffusion of elements such as hydrogen, and a solution is already
implemented in some industry sectors.
 Diffusion Coating

With low carbon steel, the surface can be enriched by diffusion of C or N into
surface
• Carburizing
– Heat steel to austenitic range (850-950 ºC) in a carbon rich environment,
then quench and temper
• Nitriding
– Nitrogen diffusion into steels occurs around 500-560 ºC to form a thin hard
surface
– Good for Cr, V, W, and Mo steels. Will embrittle surface of Aluminum.
• Metal Diffusion
– Chromizing – Chromium diffuses into surface to form corrosion resistant
layer.
• Take care with carbon steels as surface will decarburize
– Aluminizing – Used to increase the high temperature corrosion resistance of
steels and superalloys